Flexible connectors and methods of manufacturing same

ABSTRACT

A flexible connector comprises a length of corrugated tubing, a polymeric sleeve aligned with the distal end of the length of corrugated tubing, and a length of mesh tubing extending the entire of the length of corrugated tubing and over the polymeric sleeve. The distal end of the corrugated tubing, the polymeric sleeve, and the distal end of the length of mesh tubing are received in a sleeve which is formed integrally with an end piece. The sleeve is crimped into permanent retaining engagement with the length of corrugated tubing, the polymeric sleeve, and the length of mesh tubing. The end piece functions to secure the flexible connector into engagement with an adjacent component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of applicationSer. No. 10/689,279 filed Oct. 20, 2003, currently pending.

TECHNICAL FIELD

This invention relates generally to flexible connectors of the typeutilized in conjunction with fire hoses and in similar applications, andmore particularly to flexible connectors which are less expensive tomanufacture as compared with the prior art.

BACKGROUND AND SUMMARY OF THE INVENTION

Referring to FIGS. 1A and 1B, there is shown a typical prior artflexible connector 10. The flexible connector 10 includes a corrugatedtube 12. The function of the tube 12 is to contain fluids passingthrough the flexible connector 10 while affording flexibility thereto.The tube 12 does not have sufficient bursting strength to withstand thehigh pressures often associated with typical flexible connectorapplications.

Therefore, the flexible connector 10 may also include a mesh tube 14which surrounds the tube 12. The function of the mesh tube 14 is toprovide the necessary bursting strength without compromising theflexibility of the tube 12. As is known to those skilled in the art, thestainless steel mesh tube 14 can be omitted in low pressureapplications.

The tubes 12 and 14 extend the entire length of the flexible connector10. At each end thereof there is provide a sleeve 16. The function ofthe sleeves 16 is to facilitate manipulation of the flexible connector10 both during connection thereof to other instrumentalities and duringuse.

FIGS. 1A and 1B also illustrate the construction of the flexibleconnector 10. First, the corrugated tube 12, the mesh tube 14, and thesleeve 16 are assembled as shown in FIG. 1A, that is, with the endsthereof substantially aligned. Thereafter, a weldment 18 is formedaround the ends of the tube 12, the tube 14, and the sleeve 16. Theweldment 18 secures all three components one to another. Of course, inapplications in which the tube 14 is omitted, only the tube 12 and thesleeve 16 are secured by the weldment 18.

Following the welding step shown in FIG. 1A, a weldment 20 is employedto secure an end piece 22 at each end of the flexible connector 10. Aswill be appreciated by those skilled in the art, the end piece 22 shownin FIG. 2A is representative only. In actual practice numerous types andkinds of end pieces are utilized in the construction of flexibleconnectors.

As will therefore be understood, the construction of a prior artflexible connector requires two welding steps both of which must beprecisely executed in order that the flexible connector will be properlyconstructed. The type of welding required to properly assemble aflexible connector of the kind shown in FIGS. 1A and 1B requires theservices of highly skilled technicians having years of experience. Itwill therefore be understood that the type of flexible connector shownin FIGS. 1A and 1B and described hereinabove is relatively expensive tomanufacture.

The present invention comprises improvements in flexible connectordesign and construction which overcome the foregoing and otherdifficulties which have long since characterized the prior art. Inaccordance with the broader aspects of the invention, a flexibleconnector includes a corrugated tube and an end piece. The proximal endof the end piece and the distal end of the corrugated tube are engagedwith one another. A length of polymeric tubing is then extended over theadjacent ends of the corrugated tubing and the end piece, therebyretaining the ends of the length of corrugated tube and of the end piecein engagement with one another.

The length of polymeric tubing may be received within a length of meshtubing which extends the entire length of the corrugated tube and alsoextends over the proximal end of the end piece. A sleeve having an axiallength approximating the axial length of the polymeric tubing is thenextended over the end of the mesh tube. The sleeve is then crimpedthereby completing the manufacture of the flexible connector.

In low pressure applications, the length of mesh tubing may be omitted.In such instances the sleeve extends over the length of polymerictubing. Following the positioning of the stainless steel sleeve inalignment with the length of polymeric tubing and with the engaged endsof the corrugated tube and the end piece, the sleeve is crimped therebycompleting the manufacture of the flexible connector.

In accordance with another embodiment of the invention the end piece andthe sleeve comprise an integral structure. A polymeric sleeve isreceived over the distal end of the corrugating tubing, and a length ofmesh tubing is extended over the length of the corrugated tube and overthe polymeric sleeve. The subassembly comprising the corrugated tube,the polymeric sleeve, and the mesh tubing is positioned within thesleeve and the sleeve is crimped to complete the assembly of theflexible connector.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention may be had by referenceto the following Detailed Description when taken in conjunction with theaccompanying Drawings, wherein:

FIG. 1A is a perspective view illustrating a prior art flexibleconnector;

FIG. 1B is a perspective view further illustrating the prior artflexible connector of FIG. 1A;

FIG. 2 is an exploded perspective view illustrating a flexible connectorcomprising a first embodiment of the present invention and furtherillustrating the initial steps in the manufacture thereof;

FIG. 3 is a perspective view illustrating the flexible connector of FIG.2 following the completion of the manufacturing steps illustratedtherein;

FIG. 4 is a perspective view illustrating final steps in the manufactureof the flexible connector of FIG. 2;

FIG. 5 is a perspective view illustrating a flexible connectorcomprising a second embodiment of the present invention and furtherillustrating initial steps in the manufacture thereof;

FIG. 6 is a perspective view illustrating subsequent steps in themanufacture of the flexible connector of FIG. 5;

FIG. 7 is an exploded perspective view illustrating a flexible connectorcomprising a third embodiment of the invention and further illustratingthe initial steps in the manufacture thereof;

FIG. 8 is a perspective view illustrating the flexible connector of FIG.7 following implementation of the manufacturing steps illustratedtherein; and

FIG. 9 is a perspective view illustrating final steps in the manufactureof the flexible connecter of FIG. 7.

DETAILED DESCRIPTION

Referring now to the Drawings, and particularly to FIGS. 2, 3, and 4thereof, there is shown a flexible connector 30 comprising a firstembodiment of the invention. FIGS. 2, 3, and 4 further illustrate amethod of manufacturing the flexible connector.

The flexible connector 30 includes a length of corrugated tubing 32which extends substantially the entire length of the flexible connector30. The length of corrugated tubing 32 may be formed from stainlesssteel, bronze, brass, carbon, monel, other metals, various polymericmaterials, and other materials that will not be adversely affected bythe fluid that will flow through the flexible connector 30. In mostinstances an end piece 34 is provided at each end of the length ofcorrugated tubing 32. Those skilled in the art will recognize the factthat the end piece 34 is representative only and at various types andkinds of end pieces can be utilized in the practice of the invention.The end piece 34 is provided with a proximal end 36 having a-pluralityof corrugations 38.

A length of flexible polymeric tubing 40 is initially extended over theexterior of the length of corrugated tubing 32 and is moved axiallythereon sufficiently to expose the distal end thereof. Next, theproximal end 36 of the end piece 34 is engaged with the distal end ofthe length of corrugated tubing 32. Then, the length of flexible tubing40 is moved axially along the length of corrugated tubing 32 until itmoves into resilient gripping engagement with the corrugations 38 of theend piece 34. The function of the length of flexible tubing 40 is toinitially retain the proximal end 36 of the end piece 34 in engagementwith the distal end of the length of corrugated tubing 32.

After the flexible tube 40 has been positioned to retain the proximalend 36 of the end piece 34 in engagement with the distal end of thelength of corrugated tubing 32, a length of mesh tubing 42 is extendedover the entire length of the length of stainless steel corrugatedtubing 32, and over the entire length of the flexible tubing 40, andover the corrugations 38 of the end piece 34. The length of mesh tubingmay be formed from stainless steel, KAYNAR®, nylon, various textiles, orother materials depending on the requirements of particular applicationsof the invention. Assuming that an end piece is positioned at theopposite end of the length of corrugated tubing 32 and that the endpiece at the opposite end of the length tubing 32 also has corrugationsimilar to the corrugations 38, the length of mesh tubing 32 alsoextends beyond the end of the length of corrugated tubing 32 and overthe corrugations of the end piece positioned in engagement therewith.

Following the positioning of the length of mesh tubing 42 over thelength of resilient tubing 40 and over the proximal end 36 of the endpiece 34 and the distal end of the length of corrugated tubing 32, asleeve 44 is positioned over the distal end of the length of mesh tubing42 and in alignment with the length of flexible tubing 46. The resultsof the foregoing steps are illustrated in FIG. 3. The sleeve 44 may beformed from stainless steel, copper, bronze, brass, steel, or othermaterials depending on the requirements of particular applications ofthe invention.

Following the assembly steps described in the preceding paragraphs, thepartially finished flexible connector 30 is positioned in a crimping die46. Those skilled in the art will understand and appreciate the factthat the crimping die 46 is diagrammatically illustrated in FIG. 4, andthat the actual crimping die will not necessarily have the appearanceshown in FIG. 4. The function of the crimping die 46 is to crimp thesleeve 46 into permanent gripping engagement with the distal end of thelength of mesh tubing 42, the length of resilient tubing 40, thecorrugations 38 comprising the proximal end 36 of the end piece 34, andthe corrugations comprising the distal end of the length of corrugatedtubing 32. The crimping of the sleeve 46 therefore permanently retainsthe proximal end of the end piece in engagement with the distal end ofthe corrugated tube 42. Thus, following actuation of the crimping die 46at the opposite ends thereof, the fabrication of the flexible connector30 is complete.

In the case of flexible connectors intended for low pressureapplications, the length of mesh tubing 42 can be omitted. In suchinstances the sleeve 46 is aligned with the length of resilient tubing40, the corrugations 38 comprising the proximal end 36 of the end piece34, and the corrugations comprising the distal end of a length ofcorrugated tubing 34. The sleeve 46 is then crimped in the mannerdiagrammatically illustrated in FIG. 4 thereby permanently securing thecomponent parts of the flexible connector in place.

Referring to FIGS. 5 and 6, there is shown a flexible connector 50comprising a second embodiment of the present invention. The flexibleconnector 50 includes a length of corrugated tubing 52 which extendssubstantially the entire length of the flexible connector 50. Theflexible connector 50 will typically include an end piece 54 positionedat each end of the length of flexible tubing 52. Those skilled in theart will appreciate the fact that the end piece 54 is representativeonly and that various types and kinds of end pieces may be utilized inthe practice of the invention.

Regardless of the type or kind of end piece that is utilized in theconstruction of the flexible connector 50, the end piece 54 ispreferably provided with a proximal end 56 having a plurality ofcorrugations 58 formed thereon. An initial step in the manufacture ofthe flexible connector 50 comprises the engagement of the proximal end56 of the end piece 50 with the distal end of length of corrugatedtubing 52. Thereafter a length of heat shrink polymeric tubing 60 ismoved axially along the length of corrugated tubing 52 until it extendsover the corrugations 58 of the proximal end of the end piece 50 and thecorrugations comprising the distal end of the length of stainless steelcorrugated tubing 52.

Referring specifically to FIG. 6, after the length of heat shrink tubing60 is positioned over the proximal end 56 of the end piece 50 and thedistal end of the length of corrugated tubing 52, a radiation source 62is utilized to heat the length of heat shrink tubing 60. Heating of thelength of heat shrink tubing 60 causes the heat shrink tubing 60 toretract or shrink into rigid engagement with the distal end of thelength of corrugated tubing 52 and the proximal end of the end piece 50thereby securing the distal end of the length of corrugated tubing 52 inengagement with the proximal end of the end piece 50.

The succeeding steps in the manufacture of the flexible connector 50 arethe same as the latter steps in the manufacture of the flexibleconnector 30 as illustrated in FIGS. 2, 3, and 4 and describedhereinabove in conjunction therewith. Thus, the next step in themanufacture of the flexible connector 50 may involve extending a lengthof mesh tubing along the entire length of the length of corrugatedtubing 52 and over the proximal ends 56 of the end pieces 54 comprisingthe flexible connector 50. Thereafter, a sleeve similar to the stainlesssteel sleeve 44 of FIGS. 2, 3, and 4 is positioned over the distal endof the length of corrugated 52, the distal end of the length of meshtubing (if used), the proximal end of the end piece 54, and thenow-shrunk length of heat shrink tubing 60. The final step in themanufacture of the flexible connector 50 comprises the crimping of thesleeve as illustrated in FIG. 4 and described hereinabove in conjunctiontherewith. In low pressure applications the length of mesh tubing may beomitted.

Referring to FIGS. 7, 8, and 9, inclusive, there is shown a flexibleconnector 70 comprising a third embodiment of the invention. Theflexible connecter 70 differs from the embodiment of the inventionillustrated in FIGS. 2-4, inclusive, and described hereinabove inconnection therewith in that the flexible connector 70 includes a sleeve72 formed integrally with an end piece 74. The end piece 74 includes aconnecting portion 76 which may be flanged as shown in FIG. 1B, orthreaded, or grooved, or otherwise constructed depending upon therequirements of particular applications of the invention. The functionof the connecting section is to secure the flexible connector 70 inengagement with an adjacent component which may comprise a pump, anozzle, etc. The end piece 74 further includes a section 78 which may behexagonal in shape or otherwise configured for mating engagement with atool to facilitate engagement of the connecting section 76 with theadjacent component.

A length of corrugated tubing 80 extends substantially the length of aflexible connector 70. A polymeric sleeve 82 is extended over the distalend of the length of corrugated tubing 80 with the end surface 84 of thepolymeric sleeve aligned with the end surface 86 of the length ofcorrugated tubing 80.

After the polymeric sleeve 82 is positioned in alignment with the distalend of the length of corrugated tubing 80, a length of mesh tubing 88 isextended over the entirety of the length of corrugated tubing 80 andover the polymeric sleeve 82. The subassembly comprising the length ofcorrugated tubing 80, the polymeric sleeve 82, and the length of meshtubing 88 is then inserted into the end of the sleeve 72 remote from theend piece 74 and is fully seated in the sleeve 72. The result of theforegoing steps is illustrated in FIG. 8.

The next step in the manufacture of the flexible connector 70 comprisescrimping the sleeve 72 into the permanent and retaining engagement withthe subassembly comprising the length of corrugated tubing 80, thepolymeric sleeve 82, and the length of mesh tubing 88. This isaccomplished by positioning the partially finished flexible connector 70in a crimping die 90. Those skilled in the art will understand andappreciate the fact that the crimping die 90 is diagrammaticallyillustrated in FIG. 9, and that the actual crimping die will notnecessarily have the appearance shown in FIG. 9. The function of thecrimping die 90 is to crimp the sleeve 72 into permanent grippingengagement with the distal end of the length of mesh tubing 88, thepolymeric sleeve 82, and the length of corrugated tubing 80. Thus,following actuation of the crimping die 90 at the opposite ends thereof,the fabrication of the flexible connector 70 is complete.

Although preferred embodiments of the invention have been illustrated inthe accompanying Drawings and described in the foregoing DetailedDescription, it will be understood that the invention is not limited tothe embodiments disclosed, but is capable of numerous rearrangements,modifications, and substitutions of parts and elements without departingfrom the spirit of the invention.

1-2. (canceled)
 3. A method of manufacturing a flexible connectorincluding the steps of: providing a length of corrugated tubing having adistal end; providing an end piece including a tubular proximal end;engaging the tubular proximal end of the end piece with the distal endof the length of corrugated tubing; providing a length of flexiblepolymeric tubing; positioning the length of flexible polymeric tubing insurrounding engagement with the distal end of the length of corrugatedtubing and the tubular proximal end of the end piece and therebyretaining the tubular proximal end of the end piece in engagement withthe distal end of the length of corrugated tubing; providing a sleeve;positioning the sleeve in a surrounding relationship to the length offlexible tubing and in a surrounding relationship to the distal end ofthe length of corrugated tubing and to the tubular proximal end of theend piece and in alignment with the length of flexible tubing; andthereafter crimping the sleeve into permanent gripping engagement withthe length of resilient tubing, the distal end of the length ofcorrugated tubing, and the tubular proximal end of the end piece.
 4. Amethod of manufacturing a flexible connector according to claim 3wherein the step of providing an end piece is further characterized byproviding an end piece including a tubular proximal end havingcorrugations extending circumferentially therearound.
 5. A method ofmanufacturing a flexible connector according to claim 3 including theadditional steps of: providing a length of mesh tubing; positioning thelength of mesh tubing in a surrounding relationship to the length offlexible polymeric tubing and in a surrounding relationship to thedistal end of the length of corrugated tubing and to the tubularproximal end of the end piece; thereafter positioning the sleeve in asurrounding relationship to the length of mesh tubing, in a surroundingrelationship to the length of flexible tubing, and in a surroundingrelationship to the distal end of corrugated tubing and to the proximalend of the end piece and in alignment with the length of flexibletubing; and thereafter crimping the sleeve into permanently grippingrelationship with the length of mesh tubing, the length of resilienttubing, the distal end of the length of corrugated tubing, and thetubular proximal end of the end piece.
 6. A method of manufacturing aflexible connector according to claim 5 wherein the step of providing anend piece including a tubular proximal end is further characterized byproviding an end piece including a tubular proximal end havingcorrugations extending circumferentially therearound.